Coating composition and fire resistant building element coated therewith



Patented June 2, 1953 v Joseph R. Parsons-omeg 111., Morton o. Higgs,

Bell, -Calii., afndjMa'ry A. Loos, Chicago, 111,, as- Si gn'Ors' tof United States Gypsum Company, Chicago, 111;; a corporation of Illinois 'NoDrawin'g; Application Serial No. 37,536

I This invention relates to roofing" arid siding materials and coating; compositions suitable for use in preparin building materials of this" type; More particularly; this invention relates" to coatroof coverings having moi-eased fire resistance than class C, that is, class B or even class A..

Accordingly, it is one object ofthisinvention to" prepare a bituminous coating material having n-j ing' compositions and roofing and siding material 5 hanced' fire-resistant qualities when tested prepared therefrom which have greatly'enhancd comparable conditions with prior art material or fire resistance. I I I the same general character. I I II I For many years wood shingles werevvid'e'ly used It is a further object of this invention to prof as roofing-materials. The Widely reco'gnize'ddispare asphalt-coated roofing capable of qualifying advantage of wood shingles; however; i's'thir eitfor at least a class B ratingtihen tested ac i trem'e flammability; 'Iheii"- extensive use c'oritinjcordancev'vith the methods devised by Underwritued' fora number (if years, however; since" slate ers Laboratories,, II1 c. I I I II I and ti1e, thef only fire-resistant shingles" on' the Itis a still furtl ier object of this invent to market inle'arly times, were expensive and very prepare fire-resistant, Weather re sistantcote heavyi A number ofyears-agmhowever; the so-' material by a. ap" d pl ocess f b fi' calledcomposition shingles"were'ihtroduo'edto the r dily a a le s' i stafidesmarket. These are pre 'area'b' 'impre nating a A still further object of this invention isthe suitablefelt with a bituminous saturant, applyprovisionof a coating composition which tsar mg to' one surfa oe'of the saturated felt a coating larly' pt ble for" use on roofs and in tire" of asphalt which may or may not hav an added" pi'epazationo'f fire-resistant shingles'an'd siding. mineralfiller, and thereafter embeddingjmineral A' Sti l furtfi r' Obje t of this invention is the granules'ifi' the asphalt coating. With" the intror vis'ion' f a pr ssfoif pr p rin fir r'e'tardint duction of compositidnsh'inglesof thischaracter; Chafing D S: nd roofing an the-useof wood shingles has rapidly diminished the fi i c 'abbvi I and-,in fact, today wood shingles are prohibited An additional object of this invention" is to lay-ordinance in many cities. The above-referred-' provide abituminous c'omnosit b characterized" to,Icomposition shingles are today competitive' by enhanced fire resistance; ease of' application" with-wood shingles in cost and offer very definite nds flity V I Q'D iOd 'Oftime to Weather advantages infireprotection over woodshing-lesziflgco t l 'p s of roof c ructions It has been appreciated, however, that prior art 1 particularly on f er S of 'd on h composition shingles of this general character, i w' as h l pTobf's-z despite the superiority to Wood, have only a lini- Fu ther and additional objects of this invert-"- it d resi t t fire, 7 tion" Will-be apparentfrom the"fo'llowihg'descrip A' rating system has been devised by Under fi0n'and the pp Cla ms. write Lab t i In t la sify us 3%} I-t'hasbeen'discovered in aocordancewiththis robflngmaterials a w fire resistance when laid invention thata'coatingcom position havingim under conditions simulating actual use in the field proved fire-retardant and'weflther-rsistive q for the particular roofing material being tested. ties'may hichcomprises'amixture This rating system and test methods employed 0f a-binder (such asasphaltytar, pitch or other are setiorth in Underwriters Laboratories Subbituminous materials) p s f m neral" ject- 55 dated August 7, 1945. This devised sysfiberss 1 fi When a t comprises fl exposure t t spread of coatingcomposition-ofthis'character is prepared flamete t and burning brand tests. The 1 and appliedto asuitabletbase material asherein fication given'a roof covering upon being subjected after described thereresults a covering Which. to these tests. depends nut only upon the manner has enhanced fire-retardant qualities and wil-lreiri which the'c'overing is applied to the roof and :Zgg g g g g i g Laboratongsftestl I w I I I I r I in I r c vermgs prepare rom 1 1 223353 5; but-also p t bituminous materials, such as asphalt and the Itself Wood like and convent onalfiller le's when laid in courses on a roof will ordinarily a v receive no ratin whatsoever in-th t t t tcairrymg out F1 Imam-On In one a,

II I g I I 8 65 y fire-retardant coatlng composition is prepared'by'. dev1sed, whil the usual pr1or art compo meltingIan asphalt and. admixing With the result-, asphalt shlngleswhen laid in the custom ry m ing melt preformed pellets of mineral wool which ner W111 generally rate in class C. It is recognized may" be obtained from any desired source. The in the roofing art that it is desirable to provide propo'r'tion' fasphaittiade'rto themine'ral'pel-A let'sis adjusted so that the'hea't'ed asphalt-pellet tested under identical conditions and compared with a similar product coated with asphalt but which contains no added mineral wool pellets.

The presence of the formed pellets in the coating composition constitutes an important feature of this invention. When the coating composition containing the pellets is subjected to fire, the asphalt becomes fluid and for some. unknown reason the pellets expand or puff up. It is believed that the resulting puffed-up, skeletal,

felt-like arrangement of fibers within the heated. fluid coating is responsible for the enhanced fire resistance of the composition. The action. also,

has a tendency to prevent the flow of hot binder along the sheet when subjected to fire conditions.

layer remains further to protect the base.

In the preparation of the coating composition and the roofing of this invention, it is usually preferable to incorporate additional mineral fibers, such as asbestos, along with the mineral wool pellets into the binder, though satisfactory results can be obtained through the sole use of the pellets and suitable binder. These additional fibers may constitute a part of the fiber pellets or may be introduced intothe binder separately to form separate discrete fibers in the coating along with the pelleted fibers. When'asbestos fibers are employed as a supplement, they preferably should have a fineness modulus of about 2 or above, as will be hereinafter more fully defined. Also, in the preparation of the coating composition suitable for a fire-retardant composition sheet contemplated by this invention, it is preferred to add a filler to the asphalt along with the mineral wool pellets and supplemental fibrous material if any is used. Such fillers may comprise finely divided particles of an inorganic substance, such as ground limestone, slate flour, clay, barytes, sand, asbestine, or mixtures thereof; If desired, the filler may suitably comprise ground glass beads formed when mineral wool is made.

The binder employed in the coating composition of this invention may be any of the types customarily employed in coatings for conventional compositions used for built-up roofing, composite shingles or roofing material. Asphalt, tar, pitch or other bituminous material are il lustrative and typical. The amount of asphalt employed should be suflicient to permit the coating composition to be spread and/or extruded readily when hot over the base sheet material and to result in a weather-resistant coating composition. On theother hand, the relative proportion of asphalt should not be so great as to negative the fire-retardant effect produced by the pellets incorporated therewith. Except in special cases, the proportion of asphalt employed is suitably between about per cent and about '70 per cent of the total weight of the coating,

Even when the bituminous binder is de-. stroyed by fire, the puffed-up, skeletal, felt-like 4 and preferably within the range of 40 to 65 weight per cent. In place of asphalt, other bituminous materials, such as pitches, tars, resinous materials or blends thereof, may be used as the binder.

Though the softening point of the bituminous material or other binder may vary considerably, it is highly desirable that the composition of this invention comprised essentially of the bituminous material and fibrous pellets will have softening points designed for its intended usage. Thus the desirable softening point of the composition of this invention will vary somewhat according to its intended use. For example, if the coating composition is to be used on a steep roof, the softening point of the finished composition should be higher than if used on a fiat roof. Also the fiowability of the product should be such that it will not run over the surface to which it is applied under fire conditions. The various factors which are important in determining softening points and fiowability under fire conditions are the softening point of the binder per se, amount of filler, amount and character of the pellets, granular coating on the product, etc. An asphalt which is suitable for use in the composition of this invention is a blown asphalt having a softening point between about 180 and about 240 F.

In a preferred form of the invention, both mineral wool pellets and asbestos fibers are employed. The asbestos fiber may be added directly to the mineral wool prior to or during pelleting, or the asbestos fibers may be separately incorporated into the coating as discrete fibers. Asbestos fiber shorter than No. 6 is preferably formed into pellets with the mineral wool, while asbestos fiber of grade No. 6 or longer is preferably separately incorporated into the coat-.

ing.

Thus, in accordance with a preferred form of the invention, the range in proportions of the various ingredients is as follows:

Weight As previously stated, the asbestos fibers employed in conjunction with the mineral wool pellets preferably should have a fineness modulus above about 2. Thus one sample of a '7-R grade asbestos fiber, which is finer than No. 6 grade, was subjected to a standard screen analysis wherein 43.4 per cent was retained on a 14 mesh screen, 27.0 per cent passed through 14 mesh but was retained on 28 mesh, 10.2 per cent passed through a 28 mesh screen but was retained on a 48 mesh, 5.5 per cent passed through a 48 mesh but was retained on a mesh, and 14.6 per cent passed through a 100 mesh. This sample has a fineness modulus of about 2.81. The fineness modulus is computed from the above indicated screen analysis by adding the cumulative total per cents retained on each screen and dividing the total by 100. This is a well known method for classifying asbestos fibers. The grades of asbestos mentioned inthe present specification are those set up by the Quebec Asbestos Producers Association. These grades are more fully set forth in the Canadian Department of Mines Bulletin No. 70? (1931), and are also described in the United States Bureau of Mines Bulletin 5. N9. .03 on Asbestos (19.37) starting on page These designations are fully accepted by the; trade and are thoroughly understood by .those skilled in the art of dealing with asbestos and asbestos products. In this connection see. also. olumn -6 of United States Patent No. 2,569,399 of Burns and Larrison, at lines 11 through 67'. Another sample of 7-H. grade asbestos from a difierent source was subjected to. an identical screen analysis and was found to have a fineness modulus of 1.66. This latter product was not so. satisfactory in producing the fire-retardant composition of" this inventionas was the asbestoshavlng the fineness modulus of 2.81. Generally speaking, the asbestos fibers employed should have a fineness. modulus above about 2. If the fibers are No. 6 gradeor longer, they are preferably incorporated separately into the coating. composition as suggested above. It is preferred to employ more than about weight per cent of pellets in order to impart the desired. fire-retardant qualities. However, the pellets usually should not be present in an amount greater than about 25 weight per cent because of difficulties incident to application of the composition to a base sheet to form a continuous protective coatmg.

The mineral fiber pellets that are employed in the coating composition of this invention are preferably those that are prepared from mineral wool which may be blown from rock, slag, glass or any ingredients or mixtures thereof commonly employed for making mineral or glass wool. In order to prepare suitable pellets from mineral wool, ordinary mineral wool of commerce is, for example, passed through a hammer mill, whereby the mineral wool is chopped into about one inch pieces. One part by weight of'the thuschoppedmineral wool is-then mixed with at least about two partsby-weight of water and the resulting mixture is agitated as bystirring in a suitable mixer. This agitation causes the pieces ofmineral wool to form tightly rolled pellets of varying size. The size of pellets formed will depend upon a. number of factors, such asspeed of agitation, fiber diameter, nature and character of' the fibers, type of' mixer, etc. A mixing machine has been found satisfactory for the purpose. The mixer may be provided with a 21 inch diameter bowl and a 12 inch wirewhip revolving at a rate of 300 R. P. M. The mineral wool fibers suitable for pelleting should be flexible. in char-. acter and preferably have a diameter-less than about 8 microns. After the pellets have beenformed, excess water isdrained therefrom and the pellets are dried. These pellets maybe-used: directly in the coating composition of this in-. vention. If desired, the asbestos fiber. maybe pelleted, together with the mineral. wool, by adding it to the mineral wool-water-slurry near the end of the pelleting cycle. This may be effected by adding about one-half" part or more: byweight of asbestos fibers, preferablyihaving a fineness modulus greater than about 2 as above: defined, but preferably not longer than No. 6

grade, to the mixture of water and mineralwool pellets and continuing the stirring of the result.-v ing. slurry for a short period in order-thatLthe wool pellets have asbestos fibers incorporated:

therewith. Thereafter the asbestosfiber-mineral wool pellets are drained and'dried' and may be incorporated into the binder. The dryingof'thepellets may in any event. be readily eifectedby tumbling the pellets in a heatedbhamber or a.

rotary drier, it being-preferablethat the. pellets.

be. inmotion during the. drying step. If'desired, the dried pelleted woolmaybe screened or airseparated to remove beads and shot. The foregoing method for preparing the pellets is broadly disclosed and claimed the copending application of George W. Baker, Serial No. 83,237,, filed March 24', 1949 and assigned to the same. as.- signee as this application.

In the eventthat asbestos fiber is used in association with the mineral wool pellets, as is preferred, then the asbestos fiber may be incorporated into the final coating in either of two ways. It maybeseparately added to the molten bined with the mineral wool pellets directly, as.

above indicated, whereby the pellets of combined mineral wool and asbestos are incorporated into; the molten asphalt. Such shorter asbestos fibers are preferably' sufficiently long to have a fineness modulus above about 2.

Eor a more complete understanding of this invention, reference will be made to the following specific examples which are intended to be illustrative, but not restrictive, of this present invention.

Example I coating composition having the; following ormu at n. was prepar d wh re n h propertions; indicated; are in parts by weight:

The asphalt was of the Mid Continent blown variety having a ball and" ring softening point of about;21 0. F2, and the ground. limestone wasthe usual powdered limestone.- that is employed as a. filler for asphalt compositions. ofthis general character. The asbestos-mineral wool pellets were prepared'by the wet methodindicated above wherein asbestos fibers of 7R, grade having a.

and theasbestos-mineral wool pellets were stirred directly. into the-molten asphalt in orderto obtainamixture containing filler and pellets uniformly distributed therethroughout. The hot fluidcoating was :thenappli-ed'to-a base sheet of asphalt-impregnated felt by'a doctor roll. The coating: while a hot was readily spreadableby the doctor roll and was" applied in an amount of about; 38 pounds-per factory square (IOB-square feet); of-thebasefelt. Theho't coating was-then coveredzwithi a layer of mineral granules-whichwere embeddedin the-coatingbya pressure roll to-formon cooling a surfaced composite sheet. The: mineralgranules served to protect the-exposed layer of the coating composition and were bounddirectlythereto by the binding action of the asphalt. The resultin composite sheet may-- bewcut into shingles or formed into rolls. Thesecoated-sheets qualified for atleast a class-B lin- (lei-writers Laboratories rating with respect to fire resistance when applied to a test structure in coverages comparable to those in use under service conditions.

Example II A coating composition having the following formulation in parts by weight was prepared and applied to an asphalt-impregnated base sheet in the manner indicated in Example I:-

Asphalt 60.0

Ground limestone filler 23.5 Asbestos-mineral wool pellets 16.5

The several ingredients were the same as those specified in Example I, except that the asbestos fibers were a 7-K grade. The composite shingles and coated felts prepared therefrom had markedly enhanced fire-retardant qualities.

Example III A coating composition having the following formulation in parts by weight was prepared:

The asphalt and filler were the same as those indicated in Example I. The mineral wool pellets were prepared separately by a wet method, as indicated above, without asbestos fibers and the asbestos fibers were separately added to the hot asphalt with the pellets and the filler. The resulting composite sheet, coated in the manner indicated in Example I, had increased fire-resistant qualities. It will be noted that a 7-K grade of asbestos fiber was used in this example.

Ezrample IV A composition which contained no asbestos having the following formula in parts by Weight was also prepared:

Asphalt Ground limestone filler 30 Mineral wool pellets 20 This composition also exhibited improved fireretardant qualities, but it is preferred to utilize asbemos fibers as previously indicated.

In the foregoing it has been suggested that pellets prepared by a. wet method have been found to be very satisfactory for the preparation of the coating composition. However, if'desired, the pellets may also be prepared by any suitable dry method. The size of the mineral wool pellets and their density in pounds per cubic foot (dry basis) may vary widely; however, it is preferred to employ small pellets of varying size, all of which will pass a 6 mesh screen. It is permissible to employ a mixture of pellets substantially all of which will pass a 3 mesh screen but will be retained on a 20 mesh screen.

With respect to the density of the pellets employed, this may vary widely between about 6 and 20 pounds per cubic foot, depending upon the diameter of the wool fibers, fiber length, resiliency of fibers, and the amount of beads or shot in the product. The density is preferably between 10 and 12 pounds per cubic foot on a bead-free basis.

As suggested above, at least a portion of the beads may be screened or aim-separated from the pellets and the beads may be ground and employed as at least a part of the filler in the coating composition.

In the foregoing it has been pointed out that the coating composition is preferably applied to any base sheet to prepare roofing or siding elements. The amount of coating so applied may vary between about as and about 60 pounds per factorysquare.

As mentioned above the mix containing the" pellets and bituminous binders with or without conventional fillers, such as limestone, mica, etc., may be applied directly to various surfaces and roofs. Its use is particularly efiective' on socalled fiat roofs, where the roofing is built up in several layers of felt with intermediate moppings of asphalt courses. A final gravel covering is generally embedded in the top bituminous plastic or coating layer. The improved composition of this invention can replace any or all layers of the said asphalt or bituminous courses and the: finished structure will have the enhanced fireresistant qualities described hereinabove.

The new coating composition and composite sheet material of this invention have been foundto have markedly enhanced fire resistance. The reason for this resistance in products of this character is not clearly understood at the present time. However, it is presently believed that these qualities may be the result oi the tendency of the pellets under the influence of high temperature resulting from fire to unroll or expand. The so-expanded pellets of mineral fibers have a tendency to interlock and interfelt with themselves and with the other fibers or mineral matter that may be present in the composition to form a tenacious reinforcement for the coating composition, thus providing an insulating skeletonwhich projects the combustible surfaces on which the roofing or siding is erected. It will also have a tendency to prevent the hot asphalt of the coating composition from flowing.

While the foregoing constitutes an attempt to explain the phenomenon observed with the coating composition of the invention, it will be un-- derstood that the invention is not to be limited. by the theories herein advanced to explain the observed beneficial results.

While several particular embodiments of this invention are suggested above, it will be understood; of course, that the invention is not to be limited thereto, since many modifications may be made, and it is contemplated, therefore, by the appended claims, to cover any such modifications as fall within the true spirit and scope of this invention. We claim:

ently combustible base-sheet material to form therewith a relatively fire-resistant building covering material comprising a filled thermoplasl. A coating composition applicable to inhercovering material comprising a filled thermoplastic bituminous binder containing about 50% by weight of asphalt, about 35% by weight of a ground mineral filler, and about by weight of small tightly rolled up masses consisting of a mixture of asbestos fibers and mineral wool in the proportions of about one of the former to two of the latter, said masses being of a size to pass through a 6-mesh screen.

3. A coating composition, applicable to inherently combustible base-sheet material to form therewith a relatively fire-resistant buildingcovering material comprising a filled thermoplastic bituminous binder containing about 60% by weight of asphalt, about 23.5% of ground limestone filler, and about 16.5% of small tightly rolled up masses of a mixture of asbestos fibers and mineral wool in the proportions of about one of the former to two of the latter, said masses being of a size to pass through a 6-mesh screen.

4. A coating composition applicable to inherently combustible base-sheet material to form therewith a relatively fire-resistant buildingcovering material comprising a filled thermoplastic bituminous binder containing about 50% by weight of asphalt, about 26% of ground limestone filler, about 10% of asbestos fibers, and about 14% of small tightly rolled up mineral wool masses having a diameter such that they will pass through a 3-mesh screen but be retained on a mesh screen.

5. A coating composition applicable to inherently combustible base-sheet material to form therewith a relatively fire-resistant buildingcovering material comprising a filled thermoplastic bituminous binder containing about 50% by weight of asphalt, about of ground limestone filler, and about 20% of small tightly rolled up mineral wool masses having a diameter such that they will pass through a B-mesh screen but be retained on a 20-mesh screen.

6. A building element having waterand fire- 10 resistant qualities, comprising an inherently combustible base-sheet material coated with the composition of claim 1.

7. A building element having waterand fireresistant qualities, comprising an inherently combustible base-sheet material coated with the composition of claim 2.

8. A building element having waterand fireresistant qualities, comprising an inherently combustible base-sheet material coated with the composition of claim 3.

9. A building element having waterand fireresistant qualities, comprising an inherently combustible base-sheet material coated with the composition of claim 4.

10. A building element havin waterand fireresistant qualities, comprising an inherently combustible base-sheet material coated with the composition of claim 5.

JOSEPH R. PARSONS. MORTON C. HIGGS. MARY A. LOOS.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 351,611 Alexander Oct. 26, 1886 775,636 Rugen et al Nov. 22, 1904 1,190,505 Boardman July 11, 1916 1,750,725 Miller Mar. 18, 1930 1,770,767 Collings et a1 July 15, 1930 1,850,680 Levin 'Mar. 22, 1932 2,060,295 Finefrock et al Nov. 10, 1936 2,157,696 Greider et a1 May 9, 1939 2,275,816 Ericson Mar. 10, 1942 2,311,613 Slayter Feb. 16, 1943 2,326,723 Fasold et a1 Aug. 10, 1943 2,354,593 Greider et al July 25, 1944 2,375,284 Coss May 8, 1945 2,424,234 Greider et al July 22, 1947 2,458,143 Burns Jan. 4, 1949 

1. A COATING COMPOSITION APPLICABLE TO INHERENTLY COMBUSTIBLE BASE-SHEET MATERIAL TO FORM THEREWITH A RELATIVELY FIRE-RESISTANT BUILDINGCOVERING MATERIAL COMPRISING A FILLED THERMOPLASTIC BITUMINOUS BINDER CONTAINING FROM ABOUT 30% TO ABOUT 70% BY WEIGHT OF ASPHALT, FROM ABOUT 10% TO ABOUT 25% BY WEIGHT OF SMALL TIGHTLY ROLLED UP MINERAL WOOL MASSES HAVING A DIAMETER SUCH THAT THEY WILL PASS THROUGH A 3-MESH SCREEN BUT BE RETAINED ON A 20-MESH SCREEN, AND ENOUGH OF AN INORGANIC FILLER FROM THE GROUP CONSISTING OF GROUND MINERALS AND ASBESTOS TO MAKE 100% BY WEIGHT.
 6. A BUILDING ELEMENT HAVING AND FIRERESISTANT QUALITIES, COMPRISING AN INHERENTLY COMBUSTIBLE BASE-SHEET MATERIAL COATED WITH THE COMPOSITION OF CLAIM
 1. 